Automatic print speed control for indicia printer

ABSTRACT

A label printing device and method include a proportional-integral-derivative controller and a variable speed printer motor. The variable speed printer motor is connected to the proportion-integral-derivative controller, and has an automatically optimized printing speed determined by a print duration history of one or more previously completed print jobs.

FIELD OF THE INVENTION

The invention is generally related to indicia printers, and, more specifically, to indicia printers having automatic print speed control.

BACKGROUND

Decodable indicia are graphical representations of data, the most common of which are one dimensional (1D) and two dimensional (2D) barcodes. 1D barcodes are images that represent data by varying the widths and spacing of parallel lines. 2D barcodes are also images that represent data, but in addition to the parallel lines or bars, 2D barcodes can further include rectangles, dots, hexagons and other geometric patterns in two dimensions.

Decodable indicia are commonly printed on labels by indicia printers, which operate at relatively high printing speeds. Certain types of indicia print jobs, such as the more complicated 2D barcodes, require longer times to send to a printer and/or being processed by a corresponding printer language interpreter, than the time actually required to feed and print the label. As shown for example in FIG. 4, when these types of print jobs are sent in sequence to the indicia printer, frequently the indicia printer will decelerate and sometimes stop between printing each label as the indicia printer waits from the printer language interpreter to receiving and process the next print job. Frequent deceleration and stops renders lower print precision, an uneven noise environment, and wear and tear on indicia printer parts, such as a print motor.

SUMMARY

In one aspect, the invention embraces a method for printing a label using a variable speed printer that optimizes a printing speed of the variable speed printer through a proportional-integral-derivative controller for a new print job based on a print processing duration history of one or more previously completed print jobs; and automatically adjusts the printing speed based on the optimized printing speed.

In an embodiment, the print duration is a length of time extending from an actuation of a print job to a completion of the print job.

In an embodiment, optimizing the printing speed includes storing the print duration and print processing duration history of one or more previously completed print jobs.

In another embodiment, optimizing the printing speed includes capturing and storing a first time stamp of when a new print job is actuated.

In yet another embodiment, optimizing the printing speed includes calculating a theoretical print duration of the new print job starting from the first time stamp, by determining a print duration ratio of a print media length to a current printing speed.

In another embodiment, optimizing the printing speed includes storing a second time stamp of when a subsequent print job is queued.

In another embodiment, optimizing the printing speed includes calculating a difference between the theoretical print duration of the new print job and a print processing duration of one or more of the previously completed print jobs to produce an error value.

In an embodiment, when the error value is positive, the proportional-integral-derivative controller automatically decreases the printing speed of the variable printer to adjust the error value to approximately zero.

In an embodiment, when the error value is negative, the proportional-integral-derivative controller automatically increases the printing speed of the variable printer to adjust the error value to approximately zero.

In another embodiment, the print duration of the new print job is approximately equal to or greater than a print processing duration for a subsequent print job.

In yet another embodiment, the print processing duration is a length of time extending from an input of the subsequent print job into the queue to an output of the subsequent print job to the variable speed printer.

In an embodiment, the variable speed printer is a barcode printer.

In an embodiment, the print duration history is an average of print durations for two or more previously completed print jobs.

In another aspect, the invention embraces a barcode label printing device having a proportional-integral-derivative controller; and a variable speed printer motor connected to the proportion-integral-derivative controller, and having an automatically optimized printing speed determined by a print duration and a print processing duration history of one or more previously completed print jobs.

In an embodiment, the barcode label printing device includes a marker system connected to the variable speed printer and having a thermal print head.

In an embodiment, the print duration is a length of time extending from an actuation of a print job to a completion of the print job.

In another embodiment, the optimized printing speed is a different between a theoretical print duration of a current print job and the print processing duration history.

In an embodiment, the theoretical print duration of the new print job is a print duration ration of a print media length to a current printing speed.

In another embodiment, when the difference between the theoretical print duration and the print processing duration is negative, the optimized printing speed is higher than when the difference is positive.

In yet another embodiment, the print duration of the current print job is approximately equal to or greater than a print processing duration of a subsequently queued print job.

The foregoing illustrative summary, as well as other exemplary objectives and/or advantages of the invention, and the manner in which the same are accomplished, are further explained within the following detailed description and its accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described by way of example, with reference to the accompanying Figures, of which:

FIG. 1 is a perspective view of an indicia label printing device;

FIG. 2 is a schematic diagram of a control feedback system using a proportion-integral-derivative controller;

FIG. 3 is a diagram of a data processing device;

FIG. 4 is a diagram showing printing speed of a variable speed printer motor when a print processing time exceeds a label print time;

FIG. 5 is a diagram showing a proportional-integral-derivative controller optimized printing speed of the variable speed printer motor when print processing time is equal to the label print time; and

FIG. 6 is a block diagram of a method of optimizing printing speed using the proportional-integral-derivative controller.

DETAILED DESCRIPTION

In an embodiment shown in FIG. 1, an indicia label printing device 1 includes a proportional-integral-derivative controller 11 (“PID controller”), a variable speed printer motor 12, a marker system 13, and print media 14 having labels 14 a. In an embodiment, the indicial label printing device 1 is a barcode printer.

As shown in an embodiment of FIG. 1, the variable speed printer motor 23 is connected to the PID controller 11, which operates as a closed control loop feedback mechanism that automatically optimizes a printing speed of the variable speed printer motor 23 using a print processing duration Dn history of one or more previously completed print jobs. See also, FIG. 2 for a control feedback system 300 utilized by the PID controller 11.

As shown in an embodiment of FIG. 1, the marker system 13 is connected to the variable speed printer motor 12 and includes a thermal print head 12 a.

The indicia label printing device 1 is connected to a computing device 500. In an embodiment shown in FIG. 3, the computing device 500, includes one or more of a processing unit 502, memory 503, removable storage 510, and non-removable storage 512. The computing device 500 can be a computer, a laptop, a tablet, or other computing device including the same or similar elements as illustrated and described with regard to FIG. 3. Although the various data storage elements are illustrated as part of the computer 500, the storage may also or alternatively include cloud-based storage accessible via a network, such as the Internet.

Memory 503 can include volatile memory 514 and non-volatile memory 508. Computer 500 may include—or have access to a computing environment that includes—a variety of computer-readable media, such as volatile memory 514 and non-volatile memory 508, removable storage 510 and non-removable storage 512. Computer storage includes random access memory (RAM), read only memory (ROM), erasable programmable read-only memory (EPROM) & electrically erasable programmable read-only memory (EEPROM), flash memory or other memory technologies, compact disc read-only memory (CD ROM), Digital Versatile Disks (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium capable of storing computer-readable instructions known to those of ordinary skill in the art.

In another embodiment shown in FIG. 5, the computer 500 can include or have access to a computing environment that has an input 506, output 504, and a communication connection 516. Output 504 includes a display device, such as a touchscreen, that also may serve as an input device. The input 506 can include one or more of a touchscreen, touchpad, mouse, keyboard, camera, one or more device-specific buttons, one or more sensors integrated within or coupled via wired or wireless data connections to the computer 500, and other input devices. In an embodiment, the computer 500 can operate in a networked environment using a communication connection to connect to one or more remote computers (not shown), such as database servers. The remote computer can be a personal computer (PC), server, router, network PC, a peer device or other common network node, or the like commonly known to those of ordinary skill in the art. The communication connection can be a Local Area Network (LAN), a Wide Area Network (WAN), cellular, WiFi, Bluetooth, or other commonly known networks.

Computer-readable instructions stored on a computer-readable medium are executable by the processing unit 502 of the computer 500. A hard drive, CD-ROM, and RAM are examples of articles, including a non-transitory computer-readable medium like a storage device. The terms “computer-readable medium” and “storage device” generally excludes carrier waves. For example, a computer program 518 capable of providing a generic technique to perform access control check for data access and/or for doing an operation on one of the servers in a component object model (COM) based system can be included on a CD-ROM and loaded from the CD-ROM to a hard drive. The computer-readable instructions allow computer 500 to provide generic access controls in a COM based computer network system having multiple users and servers.

Those of ordinary skill in the art would appreciate that PID controllers, in general, attempt to correct errors in a system between a measured process variable and a desired setpoint, by calculating and then outputting a corrective action that adjusts the process accordingly and rapidly, in order to minimize error over time. To accomplish this, the PID controller algorithm includes coefficients for proportional (P, K_(p)), integral (I, K_(i)), and derivative (D, K_(d)) terms, where P accounts for present values of error, I accounts for past values of error, and D accounts for predicted future values of error based on current rates of change. In the embodiments shown in FIGS. 1-6, the PID Controller 11 operates as a closed control loop feedback mechanism that automatically optimizes (i.e., determines and/or adjusts) a printing speed of the variable speed printer motor 23 using the print processing duration Dn history of one or more previously completed print jobs.

In a general embodiment, processor 502 captures and stores a first time stamp Tn of a print job n being actuated in memory 503. Specifically, processor 502 captures the first time stamp Tn at a moment when processing (parsing, rendering) of the print job is complete and the system is ready to actuate the variable speed printer motor 23. Processor 502 also determines whether a subsequent print job is in queue by flagging Fn the subsequent print job. Processor 502 sends first time stamp Tn and flag Fn to memory 503 for storage. Processor 502 calculates a total processing (parsing, rendering) time from a previous time stamp Tn−1 to first time stamp Tn to create a history of time stamps that correlate approximately with processing (parsing, rendering) time required for processor 502 to process new print job n. Processor 502 sends the historical processing (parsing, rendering) and theoretical printing duration information to the PID controller 11, which then calculates an error E value determined by comparing a theoretical printing duration N to the processing (parsing, rendering) time. The PID controller 11 automatically adjusts the current print speed S to minimize any deceleration or acceleration of the variable speed printing motor 12 by minimizing the error E value between theoretical print duration N and an actual print processing (parsing, rendering) duration Dn.

In an embodiment, a process of optimizing a printing speed of the variable speed printing motor 2 by minimizing printing speed error is described as follows:

  1. Print job n is actuated; 2. Processor 502 stores first time stamp Tn of when print job n is parsed, rendered and ready to be actuated, and stores flag Fn indicating whether a subsequent print job is in queue in memory 503; 3. If Fn-1 is true then  a. print processing (rendering, parsing) duration Dn between previous time stamp Tn-1 of a completed print job and the first time stamp Tn is calculated Dn = Tn − Tn-1; and  b. use the PID controller 11 to:   calculate theoretical print duration N based on print speed S of  the variable speed printing motor 12 and media length L where  N = L/S,   calculate error E, where E = N − Dn,   adjust the error E with offset K, to make the PID controller 11  try to increase print speed, where error E is equal to E + K, and   determine and set a new, optimized print speed S_(N).

Thus, the print processing duration Dn is a length of time extending from an actuation of a print job n to a completion of the print job n; the optimized printing speed S_(N) is a difference between a theoretical print duration N of a new print job n and the print processing duration Dn of a previous print job; and the theoretical print duration N of a new print job is a print duration ratio of a print media length L to a current printing speed S. In an embodiment, the print processing duration Dn history is the print processing durations Dn for two or more previously completed print jobs. In another embodiment, the print processing duration Dn is an average of print processing durations Dn for two or more previously completed print jobs.

In an embodiment, when the difference between the theoretical print duration N and the print processing duration Dn history of previous print jobs is negative, the optimized printing speed is higher than when the difference between the theoretical print duration N and the actual print processing duration Dn is positive.

In an embodiment, when the error E between the theoretical print duration N and the actual print processing duration Dn is positive, the PID controller 11 automatically decreases the printing speed of the variable speed printer motor 23 to adjust the error E to approximately zero. Conversely, when the error value is negative between the theoretical print duration N and the actual print processing duration Dn is positive, the PID controller 11 automatically increases the printing speed S of the variable speed printer motor 23 to adjust the error E to approximately zero. In an embodiment, the print processing duration Dn of a print job n is approximately equal to or greater than a print processing duration Dn of a subsequently queued print job n by processor 502 once the PID controller 11 has determined and set the new, optimized print speed S_(N).

As shown in FIG. 5, after the PID controller 11 has adjusted the print speed S of the variable speed printer motor 23 to the optimized print speed S_(N), the actual print processing duration Dn of the print job n is approximately equal to or greater than a print processing duration Dn for a subsequent print job. The print processing duration Dn is a length of time extending from an input of the subsequent print job into the queue to an output of the subsequent print job to the variable speed printer motor 23. Thus, as shown in FIG. 5 and in contrast to FIG. 4, when the variable speed printer motor 23 is operating at the optimized printing speed S_(N), the variable speed printer motor 23 seamlessly finishes printing Label #1 and transitions to printing Label #2 without having to accelerate or decelerate.

In an embodiment shown in FIG. 6, a method for printing a label using a variable speed printer, includes the steps of providing a indicia label printing device 1 having a PID controller 11 at block 200; connecting the indicia label printing device 1 to the computing device 500 at block 201; storing the print processing duration Dn history of one or more previously completed print jobs in memory 503 at block 202; capturing with processor 502 and storing in memory 503 a first time stamp Tn of when a new print job n is actuated at block 203; calculating with processor 502 a theoretical print duration N of the new print job n starting from the first time stamp Tn, by determining a theoretical print duration N ratio of a print media length L to a current printing speed S at block 204; storing a flag Fn of when a subsequent print job is queued at block 205; calculating a difference between the theoretical print duration N of the subsequent print job and an actual print processing duration Dn based on a previously completed print job to produce an error value E at block 206; optimizing a printing speed S of the variable speed printer motor 11 through the PID controller 11 based on a print processing duration Dn history of the completed print job or a print processing duration Dn history calculated from an average print processing duration Dn of two or more previously completed print jobs n at block 207; and automatically adjusting the printing speed S of the variable speed printer motor 11 based on the optimized printing speed S_(N) for the subsequent print job, such that the actual print duration N of the new print job n is equal to or greater than the print processing duration Dn of the subsequently queued print job at block 208.

To supplement the present disclosure, this application incorporates entirely by reference the following commonly assigned patents, patent application publications, and patent applications:

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In the specification and/or figures, typical embodiments of the invention have been disclosed. The invention is not limited to such exemplary embodiments. The use of the term “and/or” includes any and all combinations of one or more of the associated listed items. The figures are schematic representations and so are not necessarily drawn to scale. Unless otherwise noted, specific terms have been used in a generic and descriptive sense and not for purposes of limitation. The use of the terms “first,” “second,” “third,” etc. are used as labels, and are not intended to impose numerical requirements upon their subjects, unless clearly stated. Furthermore, references to “an embodiment” or “another embodiment” are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Moreover, unless explicitly stated otherwise, embodiments “comprising,” “including,” or “having” an element or plurality of elements having a particular property may include additional elements not having that property. 

What is claimed is:
 1. A method for printing a label using a variable speed printer, comprising the steps of: optimizing a printing speed of the variable speed printer through a proportional-integral-derivative controller for a new print job based on a print duration and print processing duration history of one or more previously completed print jobs; and automatically adjusting the printing speed based on the optimized printing speed.
 2. The method of claim 1, wherein the print duration is a length of time extending from an actuation of a print job to a completion of the print job.
 3. The method of claim 2, wherein optimizing the printing speed includes the step of storing the print duration and print processing duration history of one or more previously completed print jobs.
 4. The method of claim 3, wherein optimizing the printing speed further includes the step of capturing and storing a first time stamp of when a new print job is actuated.
 5. The method of claim 4, wherein optimizing the printing speed further includes the step of calculating a theoretical print duration of the new print job starting from the first time stamp, by determining a print duration ratio of a print media length to a current printing speed.
 6. The method of claim 5, wherein optimizing the printing speed further includes the step of storing a second time stamp of when a subsequent print job is queued.
 7. The method of claim 6, wherein optimizing the printing speed further includes the step of calculating a difference between the theoretical print duration of the new print job and a print processing duration of one or more of the previously completed print jobs to produce an error value.
 8. The method of claim 7, wherein when the error value is positive, the proportional-integral-derivative controller automatically decreases the printing speed of the variable printer to adjust the error value to approximately zero.
 9. The method of claim 8, wherein when the error value is negative, the proportional-integral-derivative controller automatically increases the printing speed of the variable printer to adjust the error value to approximately zero.
 10. The method of claim 9, wherein the print duration of the new print job is approximately equal to or greater than a print processing duration for a subsequent print job.
 11. The method of claim 10, wherein the print processing duration is a length of time extending from an input of the subsequent print job into the queue to an output of the subsequent print job to the variable speed printer.
 12. The method of claim 8, wherein the variable speed printer is a barcode printer.
 13. The method of claim 7, wherein the print duration history is an average of print durations for two or more previously completed print jobs.
 14. A barcode label printing device comprising: a proportional-integral-derivative controller; and a variable speed printer motor connected to the proportion-integral-derivative controller, and having an automatically optimized printing speed determined by a print duration and a print processing duration history of one or more previously completed print jobs.
 15. The barcode label printing device of claim 14, further comprising a marker system connected to the variable speed printer and having a thermal print head.
 16. The barcode label printing device of claim 14, wherein the print duration is a length of time extending from an actuation of a print job to a completion of the print job.
 17. The barcode label printing device of claim 16, wherein the optimized printing speed is a different between a theoretical print duration of a current print job and a print processing duration.
 18. The barcode label printing device of claim 17, wherein the theoretical print duration of the current print job is a print duration ratio of a print media length to a current printing speed.
 19. The barcode label printing device of claim 18, wherein when the difference between the theoretical print duration and the print processing duration is negative, the optimized printing speed is higher than when the difference is positive.
 20. The barcode label printing device of claim 19, wherein the print duration of the current print job is approximately equal to or greater than a print processing duration of a subsequently queued print job. 